U.S. patent number 5,207,295 [Application Number 07/771,020] was granted by the patent office on 1993-05-04 for lightweight prefabricated elevator cab.
This patent grant is currently assigned to Otis Elevator Company. Invention is credited to Louis Bialy, Eric G. Olsen.
United States Patent |
5,207,295 |
Bialy , et al. |
May 4, 1993 |
Lightweight prefabricated elevator cab
Abstract
A lightweight, prefabricated elevator cab is provided having a
wall structure with a plurality of panel sections connected to one
another by hinge seams. The integrally attached hinge seams and the
panel sections are formed from the same homogeneous material. The
hinge seams are capable of being elastically deformed.
Inventors: |
Bialy; Louis (Simsbury, CT),
Olsen; Eric G. (Woodbury, CT) |
Assignee: |
Otis Elevator Company
(Farmington, CT)
|
Family
ID: |
25090439 |
Appl.
No.: |
07/771,020 |
Filed: |
October 1, 1991 |
Current U.S.
Class: |
187/401;
160/351 |
Current CPC
Class: |
B66B
11/0226 (20130101) |
Current International
Class: |
B66B
11/02 (20060101); B66B 009/00 () |
Field of
Search: |
;187/1R ;160/135,351
;52/30,228 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Olszewski; Robert P.
Assistant Examiner: Noland; Kenneth
Attorney, Agent or Firm: Doigan; Lloyd D.
Claims
We claim:
1. A method for assembling an elevator car having a platform, in a
hoistway having a door opening, comprising:
forming a wall structure from a homogeneous material, said wall
structure comprising a plurality of panel sections and an
integrally formed flexible hinge seam formed from said homogeneous
material, said hinge seam positioned in between said panel
sections;
bending said wall structure about said hinge seam to minimize the
dimensions of said structure, thereby allowing said structure to
pass through the door opening of the elevator hoistway; and
unbending and attaching said wall structure to the platform of the
elevator car positioned within the hoistway of the elevator.
2. A method for assembling an elevator car having a platform, in a
hoistway having a door opening, comprising:
forming a wall structure from a homogeneous material, said wall
structure comprising a plurality of panel sections and an
integrally formed flexible hinge seam formed from said homogeneous
material, said hinge seam positioned in between said panel
sections;
bending said wall structure about said hinge seam to minimize the
dimensions of said structure, thereby allowing said structure to
pass through the door opening of the elevator hoistway;
unbending and attaching said wall structure to the platform of the
elevator car positioned within the hoistway of the elevator;
and
attaching a stiffening assembly to said wall structure, thereby
adding rigidity to said wall structure.
3. A lightweight prefabricated elevator cab, comprising:
a wall structure, formed of a homogeneous material, having a
plurality of panel sections, wherein each panel section is
connected to another panel section by an integrally formed hinge
seam, said hinge seam capable of being elastically deformed;
and
a stiffening assembly, having a member and a pair of lug, wherein
said lugs attached to said panel sections on each of said hinge
seam, and receive said member, thereby adding rigidity to said wall
structure.
4. A lightweight prefabricated elevator cab according to claim 3,
wherein said homogeneous panel sections have a cross-sectional
geometry with more than one layer.
5. A lightweight prefabricated elevator cab according to claim 4,
wherein said multi-layer design further comprises voids, said voids
filled with a filler material.
6. A lightweight prefabricated elevator cab according to claim 3,
wherein said homogeneous panel sections have a cross-section
geometry of a single layer.
7. A lightweight prefabricated elevator cab according to claim 3,
further comprising a roof section formed from said homogeneous
material, connected to one of said panel sections by a hinge seam
integrally attached to said panel section and formed of said
homogeneous material, said hinge seam capable of being elastically
deformed.
8. A lightweight prefabricated elevator cab, formed of a composite
material comprising:
a wall structure, formed of a homogeneous material, having a
plurality of panel sections, wherein each panel section is
connected to another panel section by an integrally formed hinge
seam, said hinge seam capable of being elastically deformed;
and
a stiffening assembly, having a member and a pair of lug, wherein
said lug attached to said panel sections on each of said hinge
seam, and receive said member, thereby adding rigidity to said wall
structure.
9. A lightweight prefabricated elevator cab formed of a composite
material according to claim 8, wherein said homogeneous panel
sections have a cross-sectional geometry with more than one
layer.
10. A lightweight prefabricated elevator cab formed of a composite
material according to claim 9, wherein said multi-layer design
further comprises voids, said voids filled with a filler
material.
11. A lightweight prefabricated elevator cab formed of a composite
material according to claim 8, wherein said homogeneous panel
sections having a cross-section geometry of a single layer.
12. A lightweight prefabricated elevator cab according to claim 8,
further comprising a roof section formed from said homogeneous
material, connected to one of said panel sections by a hinge seam
integrally attached to said panel section and formed of said
homogeneous material, said hinge seam capable of being elastically
deformed.
Description
DESCRIPTION
1. Technical Field
This invention relates to elevators and more particularly to
elevator cabs.
2. Background Art
In elevator systems, passengers ride in an elevator car suspended
within the hoistway of the elevator. The elevator car includes a
cab section and a platform. The cab section rests atop the
platform, to which lifting equipment is typically attached. The
lifting equipment, which lowers and raises the car within the
hoistway, may consist of sheaves, cables, and drives or
alternatively a hydraulically powered arrangement.
Typically, the cab section begins with a skeletal structure of
rigid members. The individual rigid members are passed through a
narrow hoistway door opening during assembly of the skeletal
structure. Wall panels, which vary depending on the application,
are subsequently attached to the "skeleton", thereby forming the
wall structure of the cab section. Once the structure is complete,
control panels, hardware, and lighting fixtures are installed
within the cab. On-site cab construction as described is generally
time consuming and expensive.
Cab sections comprising a rigid support structure and wall panels
tend to be heavy. The excessive weight results from the inability
of the wall panels to support themselves. Heavy cabs require
sturdier elevator components including, most significantly, more
powerful elevator drives, which are more expensive to initially
purchase and then to later operate. Moreover, in hydraulic
elevators excessive weight is even more significant because no
regeneration is available and therefore the hydraulic cylinder
lifts the entire weight of the cab and the load.
In sum, what is needed is a cab for an elevator car which minimizes
installation cost and maximizes operating efficiency.
DISCLOSURE OF THE INVENTION
It is, therefore, an object of the present invention to provide a
lightweight elevator cab which, by its' reduced weight, increases
the efficiency of the elevator.
It is a further object of the present invention to provide a
prefabricated elevator cab which minimizes construction costs.
It is a still further object of the present invention to improve
the acoustic barrier properties of an elevator cab.
It is a still further object of the present invention to provide an
elevator cab that may be installed partially assembled, thereby
minimizing assembly time and consequently cost.
According to the present invention, a lightweight, prefabricated
cab is provided which can be temporarily, elastically deformed to
allow the cab to pass through the hoistway entrance and into the
hoistway.
According further to the present invention, a wall structure is
provided which includes a plurality of panel sections, containing
one or more hinge seams. The hinge seam(s) possess greater
flexibility than the panel sections, thereby allowing the wall
structure to be temporarily, elastically deformed, by bending the
structure at the hinge seam(s).
According to one aspect of the present invention, a stiffening
assembly is provided which communicates with the wall structure.
The stiffening assembly adds rigidity to the hinge seams, thereby
increasing the rigidity of the entire wall structure.
According to another aspect of the present invention a wall
structure material is provided which is a blow-molded,
injection-molded, or otherwise formed plastic or composite
material. The wall structure is constructed in a single or
multi-layer design and is capable of structural self support.
An advantage to the present invention is the increased efficiency a
lightweight cab enjoys over the heavy style cabs known in the art.
A lighter cab, and consequently lighter car, consumes less drive
energy. Moreover, a lightweight cab permits the use of less
powerful drives and less massive sheaves. Elevator manufacturing
costs are therefore reduced.
A further advantage of the present invention is the present
invention's deformable design. The design permits the wall
structure to be installed in the hoistway in a prefabricated state.
Fabricating the wall structure in a "friendly environment" such as
a manufacturing facility, as opposed to on-site within the
hoistway, allows the elevator cab to be constructed more
efficiently, therefore less expensively.
A still further advantage of the present invention is the improved
acoustic barrier properties inherent in the deformable design of
the present invention. The integral hinge seams of the wall
structure minimize the need for seals and joint fillers, and their
associated acoustic problems.
A still further advantage of the present invention is that the
present invention may be installed partially assembled. The
deformable design of the present invention allows peripheral
hardware such as lighting fixtures, vents, blowers, operating
panels, trim panels, and drive assemblies for elevator doors to be
installed prior to the installation of the cab within the hoistway.
Here again, installing the hardware in a "friendly environment"
minimizes the cost of building the elevator.
These and other objects, features, and advantages of the present
invention will become more apparent in light of the detailed
description of the best mode embodiment thereof, as illustrated in
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded view of an elevator car, having a cab and
a platform, positioned within a hoistway of an elevator.
FIGS. 2, 2A, and 2B shows the elevator cab of FIG. 1.
FIGS. 3, 3A and 3B show the elevator cab of FIG. 1 folded. FIG. 3
shows the top view of the folded cab as well as the phantomed
outline of the cab unfolded.
FIGS. 4 and 4A show a flange attached to the base of a panel
section of FIG. 2. FIG. 4 shows the flange molded within the panel
section and FIG. 4A shows an independent flange attached to a panel
section.
FIG. 5 shows a stiffening assembly attached to the exterior of the
wall structure of FIG. 2 as well as a stiffening assembly having a
continuous member and lugs attached to the interior walls of the
wall structure.
FIG. 5A shows a diagrammatic view of a stiffening assembly attached
to the interior walls of a wall structure.
FIG. 6 shows a perspective view of a rod retainer assembly.
FIG. 6A shows a sectional view of the rod retainer assembly shown
in FIG. 6 .
BEST MODE FOR CARRYING OUT THE INVENTION
Now referring to FIG. 1, an elevator 10 comprises a hoistway 12 and
an elevator car 14. The elevator car includes a platform 16 and an
attached cab 18 which travel along rails 20 located within the
hoistway. The hoistway typically includes door openings 22
positioned at each floor of the building (not shown). The width 24
of the door opening 22 is less than the width 26 of the
hoistway.
Now referring to FIG. 2, 2A and 2B, the elevator cab 18 is
constructed from a plastic or composite wall structure 28 that
includes a plurality of panel sections 30 and at least one
integrally attached flexible hinge seam 32 capable of being
elastically deformed. The wall structure has a multi-layer
cross-section 34 which is formed by either blow-molding,
injection-molding, or otherwise forming a plastic such as
polyurethane, polyethylene, or polyvinyl chloride (PVC). In other
words, the wall structure in this embodiment would be a homogeneous
material molded or extruded into a specific cross-section geometry
for strength purposes. Applicants define homogeneous as "uniform in
composition throughout" (American Heritage Dictionary .COPYRGT.1976
). The integrally attached hinges, in this embodiment are formed of
the same homogeneous material, yet they have a cross-section which
enable them to be elastically deformed. The wall structure material
may alternatively be integrally combined with fibers or a mesh
substrate for added strength. In a second embodiment, the wall
structure has a single layer cross-section 36. Here again, the wall
structure is formed of a homogeneous material. In this embodiment,
however, the cross-section is a single layer alone. Either the
single-layer or the multi-layer configuration may also include a
metal panel 33 attached to the exterior surface of the wall
structure 28 for fire prevention purposes.
In the preferred embodiment, the panel sections 30 of the wall
structure 28 contain a filler material 38 such as foam to improve
the acoustic, heat transfer, and/or flame retardant properties of
the wall structure. Other embodiments may employ different filler
materials such as plastic, carbon fiber, or styrofoam depending on
the requirements of the application. The inner 37 and outer 39
layers of the wall structure material hold the filler material
within the panel sections. The wall structure material also forms
the integrally attached hinge seam(s) 32. Other embodiments may not
include the filler material within the cross-section of the wall
structure.
In the preferred embodiment, the corner sections 40 of the wall
structure 28 serve as rigid columns capable of bearing the load of
a cab roof 42 (FIG. 1) and whatever additional weight safety
standards dictate as necessary. A single hinge seam 32 separates
two rigid panel sections 30, thereby permitting the wall structure
28 to be folded to a configuration of minimal dimensions.
Alternatively, the panel sections may serve as columns and bear the
load applied to the cab 18. Accordingly, more than one hinge seam
may be employed to facilitate the folding.
FIG. 3, 3A and 3B illustrate the method of folding the preferred
embodiment wall structure 28, consisting of two panel sections 30
and one elastically bendable hinge seam 32. Folding or bending the
wall structure about the hinge seam(s) in the method shown allows
the entire structure to be passed through the limited width 24 of
the elevator door opening 22 and into the hoistway 12. Once the
structure is within the hoistway, the structure can be unfolded and
readily attached to the platform 16. Installing the structure as an
assembled unit allows the peripheral hardware (not shown) to be
attached prior to installation at a more economical time. Other
configurations comprising more than two panel sections and more
than one hinge seam may also be employed. In addition, a roof 44
with a second hinge seam(s) 46 may also be attached to a panel
section of the wall structure. After installation of the wall
structure within the hoistway, the roof may be further attached to
the wall structure by conventional means, for example by nuts and
bolts.
Now referring to FIG. 4 and 4A, once the wall structure 28 has been
positioned on the platform 16 within the hoistway 12, it can be
secured to the platform by bolts 46, for example. In the preferred
embodiment, the bolts pass through a flange 48 integrally molded
within the panel sections 30, which extends out from the external
surface 50 of the panel sections. The preferred embodiment further
includes webbing 52 attached to the flange, spaced at regular
intervals, for added strength. In other embodiments, the flange may
be a separate device 54 either fastened to (FIG. 4A) or molded
within (not shown) the panel sections.
Now referring to FIG. 5 and 5A, in the preferred embodiment, one or
more a stiffening assemblies 56 attach to the external surface 58
of the wall structure 28. Each stiffening assembly includes a
threaded member 60 and a pair of threaded lugs 62,64 which receive
the threaded member. The threaded lugs are fixedly molded into the
panel sections 30 of the wall structure, one on each side of the
hinge seam 32. Alternatively, the lugs may simply be fastened to
the panel sections by conventional means. In another embodiment,
one or more stiffening assemblies are employed which do not thread
together, but can be tensioned by separate means, for example by
nuts independent of the lugs, or a turnbuckle, or a cam design.
Once the stiffening assembly(s) is installed, tensioning the
assembly adds rigidity to the wall structure. The number of
stiffening assemblies required depends on factors such as the
number of hinge seams, the configuration of the cab, and the
rigidity sought. In a further embodiment, a stiffening assembly
comprising lugs and a continuous member 66, which extends around
either the inner or outer perimeter of the wall structure, may be
used.
Now referring to FIGS. 6 and 6a, in one embodiment, the
aforementioned lugs 62,64 of the stiffening assembly 56 may be
replaced by rod retainer assemblies 69. The rod retainer assemblies
include a clasp section 70, which in this embodiment is
cylindrical. The clasp section has a bored main body 72 with a
cylindrical boss 74 extending out from each end. Alternatively, the
bosses may be tapered. A wedge-shaped cutout 76 extends axially
along the entire clasp section 70, thereby exposing the center bore
78. At a minimum, the angle of the wedge cutout 76 just allows the
rod or threaded member 60 to pass through into the center bore 78.
A person skilled in the art will recognize that a variety of
different wedge angles may be used.
Once the rod or member 60 is seated in the center bore 78 of the
clasp section 70, retaining collars 80, also with a center bore,
are moved axially along the member, over the bosses 74, until
contact is made with the main body 72. The collars thereby fix the
member within the clasp section.
In the preferred embodiment, a pair of nuts 82 (FIG. 6A) secure the
collars 80 to the main body 72 of the rod retainer assembly 69, one
on each side. The nuts thread onto the threaded member 60.
Alternatively, the collars may be secured to the main body by means
such as cotter pins 84 (FIG. 6), washers, and spring clips or by
other means.
The clasp section 70 attaches to a flange 86 fastened to the wall
structure 28 by conventional means such as rivets (not shown). In
another embodiment, the clasp section is molded to the wall
structure.
Stiffening members may also be attached to the internal surfaces 68
of the wall panel structure in place of external stiffening
members, or in combination with them. In a third embodiment, no
stiffening assembly is used. The design of the hinge seams, in the
third embodiment, is such that when the wall structure is unfolded,
the wall structure rigidity is sufficient and requires no
additional measures.
Although this invention has been shown and described with respect
to detailed embodiments thereof, it will be understood by those
skilled in the art that various changes in form and detail thereof
may be made without departing from the spirit and scope of the
claimed invention.
* * * * *